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The importance of electric vehicle controllers

Author : Ruiteng E-bike

Update time : 2022-12-17 11:11:00

There are several electric vehicle controllers.
Everyone who has been in contact with electric vehicle controllers knows that electric vehicles are equipped with different types of controllers according to different models. Electric vehicle controllers can be distinguished in the following ways, among which 48V electric vehicle controllers are the most commonly used.
The types of electric vehicle controllers are divided into:
1. According to the working voltage: 24V 36V 48V 60V 64V 72V and so on.
2. According to the actual power: 250W 35OW 450W 500W 650W 800W 1000W 1200W 1500W and other different powers.

3. According to the function: without the hall, with hall, dual mode (without hall + hall), self-learning, three-speed shifting, sine wave.
4. According to the models installed: two-wheeled bicycles, two-wheeled trucks, two-wheeled electric motorcycles, three-wheeled electric vehicles, scooters, four-wheeled sightseeing bicycles, stadium, electric beach bicycles.
5. According to the standard motor: 120°, 60°.
6. According to the structure: separate type and integral type.
Separate type: The so-called separation refers to the separation of the main body of the controller and the display part. The latter is installed on the handlebar, and the controller's main body is hidden in the car body compartment or electric box, and is not exposed outside. This method shortens the connection distance between the controller and the power supply and the motor, and the appearance of the car body is simple.
Integrated: the control part and the display part are integrated into a delicate special plastic box. The box is installed in the center of the handlebar, and the panel of the box has a number of small holes with a diameter of 4-5mm, and a transparent waterproof film is applied outside. A light-emitting diode is arranged at the corresponding position in the hole to indicate the speed of the vehicle, the power supply and the remaining power of the battery.

Among them, the basic functions of the electric vehicle controller: are brake power off, speed indicator indication, reversing (three-wheeled electric vehicle), constant speed cruise, 20km/h speed limit, anti-theft alarm lock motor, handle step-less speed regulation.

How to judge the advantages and disadvantages of electric vehicle controllers ?

1. Carefully observe the workmanship
The workmanship of a controller reflects the strength of a company. Under the same conditions, workshop controllers are definitely not as good as products from large companies; manual soldering products are definitely not as good as wave soldered products; A thick controller is worse than a controller with wires cutting corners; a controller with a heavy radiator is better than a controller with a light radiator, etc. Companies that pursue materials and craftsmanship are relatively reliable, as can be seen from the comparison.
2. Comparison of temperature rise
The newly sent controller and the original controller were subjected to the blockage heating experiment under the same conditions. Both controllers removed the radiators, used a car, propped up the feet, first turned the handlebar to reach the highest speed, and immediately braked. , do not brake to prevent the controller from entering the locked-rotor protection, maintain at a very low speed for 5 seconds, release the brake, quickly reach the highest

speed, brake again, repeat the same operation, for example, 30 times, and detect the highest temperature point of the radiator. Comparing the data of the two controllers, the lower the temperature, the better. The test conditions should ensure the same current limit, the same battery capacity, and the same vehicle, and also start the test from a cold car, and maintain the same braking force and time. At the end of the test, check the tightness of the screws fixing the MOS. The looser the screw, the worse the temperature resistance of the insulating plastic particles used. In long-term use, this will cause the MOS to be damaged due to heat in advance. Install the radiator again, repeat the above test, and compare the temperature of the radiator, which can examine the heat dissipation design of the controller.

3. Observe the back pressure control ability
Choose a car with a higher power, unplug the battery, use a charger to power the electric car, connect the E-ABS enable terminal, and ensure that the brake lever switch is in good contact. Slowly turn the handle, if it is too fast, the charger cannot output a large current, which will cause Undervoltage, let the motor reach the highest speed, brake quickly, and repeat many times, there should be no MOS damage. When braking, the voltage at the output terminal of the charger will rise rapidly, which will test the instantaneous voltage limiting the capability of the controller. This test is basically ineffective if it is tested with a battery.

4. Current control capability
Connect a fully charged battery, the larger the capacity the better, let the motor reach the highest speed first, choose two motor output lines to short-circuit, repeat it, more than 30 times, there should be no MOS damage; then let the motor reach the highest speed, use the positive pole of the battery and An optional motor wire is short-circuited and repeated 30 times to test the rapid control ability of the controller. Many controllers will make a fool of themselves in this link. If there is damage, you can compare the number of times the two controllers successfully withstand short circuits, the less the worse. This part of the experiment can verify the reliability design of the controller software and hardware.
5. Check the efficiency of the controller
Turn off the Overspeed function, if any, and test the highest speed achieved by different controllers in the same car with no load, the higher the speed, the higher the efficiency and the relatively higher cruising range.

The above tests are carried out without any special equipment , and are highly operable. Extensive comparisons of controllers in terms of workmanship, temperature rise, voltage and current control, and efficiency can basically reflect the advantages and disadvantages of the controller. You can choose the above experimental method according to the situation when purchasing an electric vehicle controller, and choose a more assured electric vehicle controller.

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